Electrochemical cell module and method for manufacturing same

Abstract

The embodiments described herein include an electrochemical cell module. In some aspects, the electrochemical cell module includes a first electrochemical cell and a second electrochemical cell. The first electrochemical cell includes an anode material disposed on an anode current collector, a cathode material disposed on a cathode current collector, a separator disposed between the anode material and the cathode material, and a pouch material disposed on the anode current collector and the cathode current collector. The separator extends beyond the anode material and the cathode material, and the pouch material extends beyond the separator. The portion of the separator that extends beyond the outer edges of the anode material and the cathode material, and the portion of the pouch material that extends beyond the outer edges of the separator are folded at an angle of about 80 degrees to about 110 degrees relative to the anode material and the cathode material.

Description

[Technical field]

[0001] REFERENCE TO RELATED APPLICATIONS This application claims priority to and the benefit of U.S. Provisional Application No. 63 / 272,755, filed October 28, 2021, both of which are entitled "ELECTROCHEMICAL CELL MODULE AND METHOD FOR MANUFACTURING SAME," the disclosures of which are incorporated herein by reference in their entireties.

[0002] SUMMARY OF THE DISCLOSURE The embodiments described herein relate to electrochemical cell modules comprising a stack of electrodes and electrochemical cells. [Background technology]

[0003] Electrochemical cells can be packaged in a module case to achieve large voltages and / or capacities depending on the desired purpose. A module can contain multiple electrochemical cells to minimize risk. In other words, the effect of one defective cell can be localized to that cell, so the electroactive materials of the other cells are not contaminated. However, cell modules often contain several additional components to function properly. The extra components can have a negative impact on the volume of the module. Minimizing the dead space in a cell module can improve the volume of the module. Summary of the Invention

[0004] The embodiments described herein include an electrochemical cell module. In some aspects, the electrochemical cell module can include a first electrochemical cell. The first electrochemical cell includes an anode material disposed on an anode current collector, a cathode material disposed on a cathode current collector, a separator disposed between the anode material and the cathode material and extending beyond the anode material and the cathode material, and a pouch material covering the first electrochemical cell. The pouch material extends beyond the separator. The electrochemical cell module further includes a second electrochemical cell and a module case that houses the first electrochemical cell and the second electrochemical cell. The portion of the separator that extends beyond the outer edges of the anode material and the cathode material and the portion of the pouch material that extends beyond the outer edges of the separator are folded at an angle of about 80 degrees to about 110 degrees relative to the anode material and the cathode material.

[0005] In some embodiments, the electrochemical cell module can include a heat sink disposed between the first electrochemical cell and the second electrochemical cell. In some embodiments, the heat sink extends beyond an outer edge of the anode material and an outer edge of the cathode material, and the heat sink is folded such that a portion of the heat sink contacts an interior surface of the module case. In some embodiments, the electrochemical cell module can include a temperature sensor disposed between the first electrochemical cell and the second electrochemical cell. [Brief description of the drawings]

[0006] [Figure 1] FIG. 1 is a block diagram of an electrochemical cell module according to one embodiment. [Figure 2A] FIG. 1 is a diagram of an electrochemical cell according to one embodiment. [Figure 2B] FIG. 1 is a diagram of an electrochemical cell according to one embodiment. [Figure 3A] FIG. 1 is a diagram of an electrochemical cell module according to one embodiment. [Figure 3B] FIG. 1 is a diagram of an electrochemical cell module according to one embodiment. [Figure 3C] FIG. 1 is a diagram of an electrochemical cell module according to one embodiment. [Figure 3D] FIG. 1 is a diagram of an electrochemical cell module according to one embodiment. [Figure 3E] FIG. 1 is a diagram of an electrochemical cell module according to one embodiment. [Figure 3F] FIG. 1 is a diagram of an electrochemical cell module according to one embodiment. [Figure 4A] FIG. 1 is a diagram of an electrochemical cell module according to one embodiment. [Figure 4B] FIG. 1 is a diagram of an electrochemical cell module according to one embodiment. [Figure 5A] FIG. 1 is a diagram of an electrochemical cell module according to one embodiment. [Figure 5B] FIG. 1 is a diagram of an electrochemical cell module according to one embodiment. [Figure 5C] FIG. 1 is a diagram of an electrochemical cell module according to one embodiment. [Figure 6] FIG. 1 is a diagram of an electrochemical cell according to one embodiment. [Figure 7A] 1 illustrates a method of forming an electrochemical cell module, according to one embodiment. [Figure 7B] 1 illustrates a method of forming an electrochemical cell module, according to one embodiment. [Figure 7C] 1 illustrates a method of forming an electrochemical cell module, according to one embodiment. [Figure 7D] 1 illustrates a method of forming an electrochemical cell module, according to one embodiment. [Figure 7E] 1 illustrates a method of forming an electrochemical cell module, according to one embodiment. [Figure 8A] 1 illustrates a method of forming an electrochemical cell module, according to one embodiment. [Figure 8B] 1 illustrates a method of forming an electrochemical cell module, according to one embodiment. [Figure 8C] 1 illustrates a method of forming an electrochemical cell module, according to one embodiment. [Figure 8D]1 illustrates a method of forming an electrochemical cell module, according to one embodiment. [Figure 8E] 1 illustrates a method of forming an electrochemical cell module, according to one embodiment. [Figure 9A] 1 illustrates a method of forming an electrochemical cell module, according to one embodiment. [Figure 9B] 1 illustrates a method of forming an electrochemical cell module, according to one embodiment. [Figure 9C] 1 illustrates a method of forming an electrochemical cell module, according to one embodiment. [Figure 9D] 1 illustrates a method of forming an electrochemical cell module, according to one embodiment. [Figure 9E] 1 illustrates a method of forming an electrochemical cell module, according to one embodiment. [Figure 10A] 1 illustrates a method of forming an electrochemical cell module, according to one embodiment. [Figure 10B] 1 illustrates a method of forming an electrochemical cell module, according to one embodiment. [Figure 10C] 1 illustrates a method of forming an electrochemical cell module, according to one embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007] The embodiments described herein relate to electrochemical cell modules and methods of making the same. Unused space is a significant problem faced by large arrays of electrochemical cells. For example, the cathode and anode can be different sizes to properly maximize material utilization. Furthermore, the separator can be sized such that its length and width dimensions are larger than those of the anode and cathode, and the separator can be directly bonded to the pouch material to prevent cross contamination between the anode and cathode. By stacking multiple cells in a module, more electroactive material can be achieved per unit volume. The pouch material can also have longer length and width dimensions than the separator to help contain the electroactive material. These extensions of the separator and pouch material can result in unused space where no electroactive material is present. The extensions of the electrochemical cell stack can be folded to minimize the dead space. Examples of electrochemical cell stacks are further described in U.S. Pat. No. 10,181,587, entitled “SINGLE-POUCH BATTERY CELL AND METHOD FOR MANUFACTURING THE SAME,” filed June 17, 2016 (the “'587 Patent”), the entire disclosure of which is incorporated herein by reference.

[0008] As used herein, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, the term "member" is intended to mean a single member or a combination of members, and "material" is intended to mean one or more materials, or combinations thereof.

[0009] The term "substantially," when used in conjunction with "cylindrical," "linear," and / or other geometric relationships, is intended to convey that the structure so defined is nominally cylindrical, linear, etc. As an example, a portion of a support member described as being "substantially linear" is intended to convey that while linearity of the portion is desired, some non-linearity may occur in the "substantially linear" portion. Such non-linearity may result from manufacturing tolerances, or other practical considerations (e.g., pressure or force applied to the support member, etc.). Thus, a geometric structure modified by the term "substantially" includes such geometric characteristics within a tolerance of plus or minus 5% of the described geometric structure. For example, a "substantially linear" portion is one that defines an axis or centerline that is within ±5% of being a straight line.

[0010] As used herein, the terms "set" and "plurality" may refer to a plurality of features or a single feature having a plurality of portions. For example, when referring to a set of electrodes, the set of electrodes can be considered as one electrode having a plurality of portions, or the set of electrodes can be considered as a plurality of separate electrodes. Furthermore, for example, when referring to a plurality of electrochemical cells, the plurality of electrochemical cells can be considered as a plurality of separate electrochemical cells, or as one electrochemical cell having a plurality of portions. Thus, a set of portions or portions can include a plurality of portions that are continuous or discontinuous with each other. A plurality of particles or a plurality of materials can also be manufactured from a plurality of items that are manufactured separately and then bonded (e.g., by mixing, adhesive, or any suitable method).

[0011] As used herein, the term "semi-solid" refers to a material that is a mixture of liquid and solid phases, such as, for example, a particle suspension, a slurry, a colloidal suspension, an emulsion, a gel, or a micelle.

[0012] 1 is a block diagram of an electrochemical cell module 100 according to one embodiment. As shown, the electrochemical cell module 100 includes a first electrochemical cell 110a, a second electrochemical cell 110b (collectively referred to as electrochemical cells 110), and an outer casing 160. The electrochemical cell module 100 may also include frames 120a, 120b (collectively referred to as frames 120), a heat sink 130, a degassing region 140, and a pressure member 150.

[0013] In some embodiments, the electrochemical cells 110 can be the same as or substantially similar to the electrochemical cells described in the '587 patent. Each electrochemical cell 110 can include an anode material disposed on an anode current collector, a cathode material disposed on a cathode current collector, and a separator disposed between the anode material and the cathode material. The separator can be large enough that a portion of the separator extends beyond the outer edge of the anode material and the outer edge of the cathode material. The electrochemical cell 110 can further include a pouch material at least partially covering the anode material, the anode current collector, the cathode material, the cathode current collector, and the separator. In some embodiments, the pouch material can be in contact with the anode current collector, the cathode current collector, and / or the separator. The pouch material can be large enough that a portion of the pouch material extends beyond the outer boundary of the separator. To minimize unused space within the electrochemical cell module, the pouch material and separator can be folded against the anode and cathode materials rather than extending outwardly from the anode and cathode materials.

[0014] As shown, the electrochemical cell module 100 includes two electrochemical cells 110. In some embodiments, the electrochemical cell module 100 can include 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, at least about 20, at least about 25, at least about 30, at least about 35, at least about 40, at least about 45, at least about 50, at least about 55, at least about 60, at least about 65, at least about 70, at least about 75, at least about 80, at least about 85, at least about 90, at least about 95, or at least about 100 electrochemical cells 110, including all values ​​and ranges therebetween. In some embodiments, the electrochemical cells 110 can be connected in parallel. In some embodiments, the electrochemical cells 110 can be connected in series. In some embodiments, the electrochemical cells 110 can be connected in both series and parallel. In some embodiments, one or more of the electrochemical cells 110 can include a single unit cell. In some embodiments, one or more of the electrochemical cells 110 can include a bicell.

[0015] The stackable nature of the electrochemical cells 110 facilitates ease of manufacturing. In some embodiments, the electrochemical cells 110 can be manufactured via pick-and-place assembly. The electrochemical cells 110 can be manufactured without rolling or Z-bending to stack them. Rather, the electrochemical cells 110 can be manufactured side-by-side via a pick-and-place procedure, and the electrochemical cells 110 can be stacked on top of each other after manufacturing is complete. The pick-and-place assembly can also facilitate additional quality control (QC) testing. For example, a casting and assembly machine can manufacture the electrochemical cells 110 via pick-and-place assembly, and the electrochemical cells 110 can be stacked in a first stack. The electrochemical cells 110 can be unstacked and individually subjected to additional QC testing before being assembled into a second stack of electrochemical cell modules 100. This additional QC testing can ensure that each of the electrochemical cells 110 included in the electrochemical cell modules 100 is of high quality. In some embodiments, prior to assembly of the electrochemical cell 110 into the second stack of electrochemical cell modules 100, the electrochemical cell 110 may be inspected by infrared (IR) inspection.

[0016] The frame 120 provides support for the electrochemical cells 110. In some embodiments, the frames 120 can be stacked on top of each other. In some embodiments, the frame can include holes for connecting members (e.g., bolts, screws) to pass through. In some embodiments, the frame 120 can be constructed of plastic, polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), or any combination thereof. In some embodiments, the frame 120 can be non-flammable and / or flame retardant.

[0017] The heat sink 130 removes heat from the electrochemical cells 110 and the active materials therein. In some embodiments, the heat sink 130 may include a metal sheet. In some embodiments, the electrochemical cell module 100 may include multiple heat sinks 130. In some embodiments, a heat sink 130 may be disposed between each pair of electrochemical cells 110. In some embodiments, the heat sink 130 may be disposed intermittently between the electrochemical cells 110. In some embodiments, the heat sink 130 may be integrated into one or more of the frames 120. In some embodiments, the heat sink 130 may be in contact with the electrochemical cells 110, the frame 120, and / or the outer casing 160. In some embodiments, the heat sink 130 may be bent to contact the top and sides of the electrochemical cells 110 while also contacting the inner wall of the outer casing 160. In some embodiments, the heat sink 130 may include holes for venting.

[0018] In some embodiments, the degassing region 140 can be formed from holes in various components of the electrochemical cell module 100, and the holes can be covered once formation of the electrochemical cell module 100 is complete. In other words, the degassing region 140 can be a space region that is open to the outside environment during manufacture of the electrochemical cell module 100, and that is sealed off after manufacture and degassing are complete. Examples of such implementations are further described in U.S. Patent Publication No. 2020 / 0411825, entitled “Dual Electrolyte Electrochemical Cells, Systems, and Methods for Manufacturing Same,” filed June 26, 2020 (the “'825 Publication”), the entire disclosure of which is incorporated herein by reference.

[0019] The pressure member 150 can apply a force to the stack of electrochemical cells 110. This applied force can push against the electroactive material of the electrochemical cells 110, thereby facilitating ion transfer between adjacent electrodes. In some embodiments, the pressure member 150 can be fixedly coupled to one or more of the frames 120. As shown, the pressure member 150 is at the top of the electrochemical cell 110b near the top of the electrochemical cell module 100. In some embodiments, the pressure member 150 can be located near the bottom of the electrochemical cell module 100. In some embodiments, the pressure member 150 can be located between the electrochemical cells 110. In some embodiments, the pressure member 150 can include a spring that applies a force to the electrochemical cells 110. In some embodiments, the pressure member 150 can include a rod (e.g., a metal rod).

[0020] The external casing 160 houses the other components of the electrochemical cell module 110. The external casing 160 includes a positive terminal and a negative terminal. In some embodiments, the external casing 160 can be constructed of metal. A metal casing can be beneficial for the electrochemical cells 110 when they are connected in parallel. The external casing 160 can include an aluminum base for the positive terminal. The external casing 160 can include nickel, nickel plate, iron, and / or copper for the negative terminal. In some embodiments, jumper tabs can be used to connect the terminals. In some embodiments, the external casing 160 can include plastic on its exterior surface and metal on its interior surface. In some embodiments, in a series connection, the weld tabs of the first and last electrochemical cells in the series can be welded or mechanically connected to the inside of the external casing.

[0021] 2A-2B illustrate an electrochemical cell 210 according to one embodiment. FIG. 2A illustrates a cross-sectional view of the electrochemical cell 210, and FIG. 2B illustrates an overhead view of the electrochemical cell 210. The electrochemical cell 210 can be integrated into an electrochemical cell module, such as the electrochemical cell module 100, as described above with reference to FIG. 1. As illustrated, the electrochemical cell 210 includes an anode material 211 disposed on an anode current collector 212, a cathode material 213 disposed on a cathode current collector 214, and a separator 215 disposed between the anode material 211 and the cathode material 213. The anode current collector 212 includes an anode tab 216, and the cathode current collector 214 includes a cathode tab 217. A pouch material 218 is disposed around the exterior of the anode current collector 212 and the cathode current collector 214 to form a pouch. As shown, the anode tab 216 and the cathode tab 217 can extend to an area outside the pouch material 218. The anode tab 216 and / or the cathode tab 217 can be coupled to the anode tab and / or the cathode tab of one or more adjacent electrochemical cells in the electrochemical cell module. In some embodiments, the electrochemical cell 210 can be the same as or substantially similar to the electrochemical cell described in the '587 patent.

[0022] As shown, the pouch material 218 is of sufficient size such that the pouch material 218 extends beyond the outer edge of the separator 215. In other words, the pouch material 218 has a length that is greater than the length of the separator 215 and a width that is greater than the width of the separator 215. In some embodiments, the length of the pouch material 218 is about 100 μm, about 200 μm, about 300 μm, about 400 μm, about 500 μm, about 600 μm, about 700 μm, about 800 μm, about 900 μm, about 1 mm, about 1.5 mm, about 2 mm, about 2.5 mm, about 3 mm, about 3.5 mm, about 4 mm, about 4.5 mm, about 5 mm, about 5.5 mm, about 6 mm, about 7.5 mm, about 8.5 mm, about 9.5 mm, about 10.5 mm, about 11.5 mm, about 12.5 mm, about 13.5 mm, about 14.5 mm, about 15.5 mm, about 16.5 mm, about 17.5 mm, about 18.5 mm, about 19.5 mm, about 20.5 mm, about 21.5 mm, about 22.5 mm, about 23.5 mm, about 24.5 mm, about 25.5 mm, about 26.5 mm, about 27.5 mm, about 28.5 mm, about 29.5 mm, about 30.5 mm, about 31.5 mm, about 32.5 mm, about 33.5 mm, about 34.5 mm, about 35.5 mm, about 36.5 mm, about 37.5 mm, about 38.5 mm, about 39.5 mm, about 40.5 mm, about 41.5 mm, about It may be greater than 5 mm, about 7 mm, about 7.5 mm, about 8 mm, about 8.5 mm, about 9 mm, about 9.5 mm, about 1 cm, about 1.5 cm, about 2 cm, about 2.5 cm, about 3 cm, about 3.5 cm, about 4 cm, about 4.5 cm, about 5 cm, about 5.5 cm, about 6 cm, about 6.5 cm, about 7 cm, about 7.5 cm, about 8 cm, about 9.5 cm, or about 10 cm, including all values ​​and ranges therebetween. In some embodiments, the width of the pouch material 218 is about 100 μm, about 200 μm, about 300 μm, about 400 μm, about 500 μm, about 600 μm, about 700 μm, about 800 μm, about 900 μm, about 1 mm, about 1.5 mm, about 2 mm, about 2.5 mm, about 3 mm, about 3.5 mm, about 4 mm, about 4.5 mm, about 5 mm, about 5.5 mm, about 6 mm, about 6.5 mm, about 7.5 mm, about 8.5 mm, about 9.5 mm, about 100 μm, about 200 μm, about 300 μm, about 400 μm, about 500 μm, about 600 μm, about 700 μm, about 800 μm, about 900 μm, about 1 mm, about 1.5 mm, about 2 mm, about 2.5 mm, about 3 mm, about 3.5 mm, about 4 mm, about 4.5 mm, about 5 mm, about 5.5 mm, about 6 mm, about 7.5 mm, about 8.5 mm, about 9.5 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, about 15 mm, about 16 mm, about 17 mm, about 18 mm, about 19 mm, about 20 mm, about 21 mm, about 22 mm, about 23 mm, about 24 mm, about 25 mm, about 26 mm, about 27 mm, about 28 mm, about 29 mm, about 30 mm, about 31 mm, about 32 mm, about 33 mm, about 34 mm, about 35 mm, about 36 mm, about 37 mm, about 38 mm mm, about 7 mm, about 7.5 mm, about 8 mm, about 8.5 mm, about 9 mm, about 9.5 mm, about 1 cm, about 1.5 cm, about 2 cm, about 2.5 cm, about 3 cm, about 3.5 cm, about 4 cm, about 4.5 cm, about 5 cm, about 5.5 cm, about 6 cm, about 6.5 cm, about 7 cm, about 7.5 cm, about 8 cm, about 9.5 cm, or about 10 cm, including all values ​​and ranges therebetween.

[0023] As shown, the pouch material 218 includes a vent hole 219. The vent hole 219 allows for venting of the electrochemical cell 210 during manufacture and initial cycling of the electrochemical cell 210. In some embodiments, the vent hole 219 can be formed by laminating a portion of the outer edge of the pouch material 218 and leaving one or more portions of the outer edge of the material 218 unlaminated. In some embodiments, the vent hole 219 can remain open during operation of the electrochemical cell 210. In some embodiments, the electrochemical cell 210 can be disposed within an outer casing (e.g., the outer casing 160 as described above with reference to FIG. 1). In some embodiments, the outer casing can be hermetically sealed to prevent exposure of the electrochemical cell 210 to the external environment during operation.

[0024] 3A-3F illustrate an electrochemical cell module 300 according to one embodiment. As shown, the electrochemical cell module 300 includes electrochemical cells 310a, 310b, 310c, 310d, 310e (collectively referred to as electrochemical cells 310), heat sinks 330a, 330b, 330c, 330d, 330e (collectively referred to as heat sinks 330), a pressure member 350, an outer casing 360, and temperature sensors 370a, 370b, 370c, 370d, 370e (collectively referred to as temperature sensors 370). FIG. 3A illustrates a side view of the electrochemical cell module 300, FIG. 3B illustrates a detailed view of section B of electrochemical cell 310c, and FIG. 3C illustrates a tab bonding scheme for electrochemical cells 310. 3D shows a front view of the electrochemical cell module 300, FIG. 3E shows a rear view of the electrochemical cell module 300, and FIG. 3F shows an external view of the outer casing 360 of the electrochemical cell module 300. In some embodiments, the electrochemical cell 310, the heat sink 330, the pressure member 350, and the outer casing 360 may be the same as or substantially similar to the electrochemical cell 110, the heat sink 130, the pressure member 150, and the outer casing 360, as described above with reference to FIG. 1. Accordingly, certain aspects of the electrochemical cell 310, the heat sink 330, the pressure member 350, and the outer casing 360 will not be described in further detail herein.

[0025] 3B and 3C, the electrochemical cell 310 includes an anode material 311 disposed on an anode current collector 312, a cathode material 313 disposed on a cathode current collector 314, and a separator 315 disposed between the anode material 311 and the cathode material 313. The anode current collector 312 includes an anode tab 316, and the cathode current collector 314 includes a cathode tab 317. The electrochemical cell 310 also includes a pouch material 318 disposed around the exterior of the anode current collector 312 and the cathode current collector 314 to form a pouch. As shown, the separator 315, the cathode tab 317, and the pouch material 318 are folded at an angle relative to the anode material 311 and the cathode material 313. In some embodiments, the anode tab 316 can be folded at an angle relative to the anode material 311 and the cathode material 313. As shown, the separator 315, the cathode tab 317, and the pouch material 318 form an angle of about 90 degrees relative to the length or width dimension of the anode material 311 and the cathode material 313. In some embodiments, the separator 315, the anode tab 316, the cathode tab 317, and / or the pouch material 318 can form an angle of about 80 degrees, about 85 degrees, about 90 degrees, about 95 degrees, about 100 degrees, about 105 degrees, about 110 degrees, about 115 degrees, about 120 degrees, about 125 degrees, or about 130 degrees relative to the length or width dimension of the anode material 311 and the cathode material 313, including all values ​​and ranges therebetween. In some embodiments, the separator 315, anode tab 316, cathode tab 317, and / or pouch material 318 may be attached (eg, via an adhesive) to an inner wall of the outer casing 360.

[0026] The separator 315, cathode tab 317, and pouch material 318 are folded to minimize the distance between the outer casing 360 and the leading edge of the anode material 311 and / or cathode material 313. Minimizing this distance can minimize the amount of unused space within the electrochemical cell module 300. In some embodiments, the distance between the outer casing 360 and the leading edge of the anode material 311 and / or cathode material 313 is less than about 2 mm, less than about 1.9 mm, less than about 1.8 mm, 1.7 mm, less than about 1.6 mm, less than about 1.5 mm, less than about 1.4 mm, less than about 1.3 mm, less than about 1.2 mm, less than about 1.1 mm, less than about 1 mm, less than about 900 μm, less than about 800 μm, less than about 1.5 mm, less than about 1.5 mm, less than about 1.6 mm, less than about 1.5 mm, less than about 1.5 mm, less than about 1.6 mm, less than about 1.7 mm, less than about 1.8 mm, less than about 1.7 mm, less than about 1.6 mm, less than about 1.5 ... The thickness may be less than about 700 μm, less than about 600 μm, less than about 500 μm, less than about 400 μm, less than about 300 μm, less than about 200 μm, less than about 100 μm, less than about 90 μm, less than about 80 μm, less than about 70 μm, less than about 60 μm, less than about 50 μm, less than about 40 μm, less than about 30 μm, less than about 20 μm, or less than about 10 μm, including all values ​​and ranges therebetween.

[0027] 3C illustrates a scheme for coupling the electrochemical cell 310 to the outer casing 360 via the anode tab 316 and the cathode tab 317. As illustrated, the cathode tab 317 is oriented to fold upward relative to the electrochemical cell 310, and the anode tab 316 is oriented to fold downward relative to the electrochemical cell 310. The anode tab 316 extends out of the electrochemical cell 310 in the opposite direction compared to the cathode tab 317. This arrangement can accommodate cells connected in series. In some embodiments, the cathode tab 317 can extend out of the electrochemical cell 310 in the same direction as the anode tab 316. This arrangement can accommodate cells connected in parallel.

[0028] As shown, the outer casing 360 includes a negative terminal 362, a positive terminal 364, and a communication device 365. The negative terminal 362 is electrically coupled to one or more anode tabs 316. In some embodiments, the anode tab 316 can be coupled to a metal plate, which can be coupled to the negative terminal 362. In some embodiments, the anode tab 316 can be directly coupled to an inner wall of the outer casing 360. In some embodiments, the coupling of the anode tab 316 to the metal plate and / or the inner wall of the outer casing 360 can be by welding. In some embodiments, the negative terminal 362 can be connected to a jumper tab. The positive terminal 364 is electrically connected to one or more cathode tabs 317. In some embodiments, the cathode tab 317 can be coupled to a metal plate, which can be coupled to the positive terminal 364. In some embodiments, the cathode tab 317 can be directly coupled to an inner wall of the outer casing 360. In some embodiments, the coupling of the cathode tab 317 to the metal plate and / or the inner wall of the outer casing 360 can be done by welding. In some embodiments, the positive terminal 364 can be connected to a jumper tab.

[0029] The communication device 365 communicates information regarding the electrochemical cell module 300. In some embodiments, the communication device 365 can communicate with a user interface (e.g., a computer, a laptop computer, a desktop computer, a tablet, a mobile phone, or any other suitable device or combination thereof). In some embodiments, the communication device 365 can communicate information regarding the state of charge of the electrochemical cell 310, temperature information from the temperature sensor 370, pressure information from the interior of the exterior case 360, and / or any other desired information. In some embodiments, the communication device 365 can include a battery management system (BMS). In some embodiments, the BMS can include a printed circuit board (PCB). In some embodiments, the temperature sensor 370 and / or the electrochemical cell 310 can be electrically coupled to the PCB.

[0030] Figure 3D shows a front view of the electrochemical cell module 300, where the cathode tabs 317a, 317c and the anode tabs 316b, 316d are visible. Figure 3E shows a rear view of the electrochemical cell module 300, where the anode tabs 316a, 316c and the cathode tabs 317b, 317d are visible. As shown, the electrochemical cells 310 are arranged in series, such that the anode tab 316 of a first electrochemical cell 310 is bonded to the cathode tab 317 of a second electrochemical cell 310.

[0031] FIG. 3F shows an external view of the exterior casing 360 of the electrochemical cell module 300. As shown, the exterior casing 360 includes a venting opening 366. Gases generated during the formation of the electrochemical cell module 300 can escape from the exterior casing 360 through the venting opening 366. During the manufacture of the electrochemical cell module 300, a portion of the heat sink 330 can be opened (e.g., drilled) to vent gases from the degassing region in the electrochemical cell 310. Once the formation of the electrochemical cell module 300 is complete, the venting opening 366 can be covered and sealed. In some embodiments, the exterior casing 360 may be wrapped with a pouch or additional casing with an airtight seal to insulate the electrochemical cell module 360. In some embodiments, the exterior casing 360 can be wrapped by an aluminum pouch. In some embodiments, the exterior casing 360 can be wrapped by an aluminum casing.

[0032] In some embodiments, the electrochemical cell module 300 can include one or more heating elements (not shown). In some embodiments, the heating elements can include heating strips. In some embodiments, the heating elements can be disposed between the electrochemical cells 310 (e.g., between electrochemical cell 310a and electrochemical cell 310b). The heating elements can help maintain a high operating temperature. The heating elements can be beneficial for battery designs intended to operate at higher temperatures (e.g., at least about 25°C, at least about 30°C, at least about 35°C, at least about 40°C, at least about 45°C, or at least about 50°C). In a low temperature environment (e.g., about -20°C), the heating elements can increase the operating temperature to at least about -15°C, at least about -10°C, at least about -5°C, at least about 0°C, at least about 5°C, at least about 10°C, at least about 15°C, or at least about 25°C. In some embodiments, the heating elements can be integrated into the heat sink 330. In some embodiments, a heat sink 330 may be used to transfer heat to and from the electrochemical cell module 300 and the electrochemical cells 310 within the electrochemical cell module 300, as desired.

[0033] 4A-4B show an electrochemical cell module 400 according to one embodiment. Fig. 4A shows a front view of the electrochemical cell module 400, and Fig. 4B shows a rear view of the electrochemical cell module 400. As shown, the electrochemical cell module 400 includes electrochemical cells 410a, 410b, 410c, 410d, and 410e (collectively referred to as electrochemical cells 410), heat sinks 430a, 430b, 430c, 430d, and 430e (collectively referred to as heat sinks 430), a pressure member 450, and an exterior case 460. As shown, electrochemical cell 410 includes anode tabs 416a, 416b, 416c, and 416d (collectively referred to as anode tabs 416) and cathode tabs 417a, 417b, 417c, and 417d (collectively referred to as cathode tabs 417). As shown, exterior case 460 includes a negative terminal 462, a positive terminal 464, and a communication device 465.

[0034] In some embodiments, the electrochemical cell 410, the anode tab 416, the cathode tab 417, the heat sink 430, the pressure member 450, the outer case 460, the negative terminal 462, the positive terminal 464, and the communication device 465 may be the same as or substantially similar to the electrochemical cell 310, the anode tab 316, the cathode tab 317, the heat sink 330, the pressure member 350, the outer case 360, the negative terminal 362, the positive terminal 364, and the communication device 365, as described above with reference to Figures 3A-3F. Accordingly, certain aspects of the electrochemical cell 410, the anode tab 416, the cathode tab 417, the heat sink 430, the pressure member 450, the outer case 460, the negative terminal 462, the positive terminal 464, and the communication device 465 will not be described in detail herein. As shown, the electrochemical cells 410 are connected in parallel. In other words, the anode tabs 416 are electrically connected to one another, and the cathode tabs 417 are electrically connected to one another.

[0035] 5A-5C illustrate an electrochemical cell module 500 according to one embodiment. As shown, the electrochemical cell module 500 includes electrochemical cells 510a, 510b, 510c, 510d, 510e (collectively referred to as electrochemical cells 510), frames 520a, 520b, 520c, 520d, 520e (collectively referred to as frames 520), heat sinks 530a, 530b, 530c, 530d, 530e (collectively referred to as heat sinks 530), a pressure member 550, an outer casing 560, and temperature sensors 570a, 570b, 570c, 570d, 570e (collectively referred to as temperature sensors 570). FIG. 5A illustrates a side view of the electrochemical cell module 500, and FIG. 5B illustrates a detailed view of section B of the electrochemical cell 510c. 5C shows a detailed view of frame 520. As shown, each electrochemical cell 510 includes an anode material 511, an anode current collector 512, a cathode material 513, a cathode current collector 514, a separator 515, an anode tab (not shown), a cathode tab 517, and a pouch material 518. As shown, an outer casing 560 includes a negative terminal 562, a positive terminal 564, and a communication device 565.

[0036] In some embodiments, the electrochemical cell 510, anode material 511, anode current collector 512, cathode material 513, cathode current collector 514, separator 515, anode tab, cathode tab 517, pouch material 518, heat sink 530, pressure member 550, outer casing 560, negative terminal 562, positive terminal 564, communication device 565, and temperature sensor 570 may be any of the components described above with reference to FIGS. 3A-3F. As discussed above, the electrochemical cell 310, anode material 311, anode current collector 312, cathode material 313, cathode current collector 314, separator 315, anode tab 316, cathode tab 317, pouch material 318, heat sink 330, pressure member 350, outer casing 360, negative terminal 362, positive terminal 364, communication device 365, and temperature sensor 370 can be the same or substantially similar. Accordingly, certain aspects of the electrochemical cell 510, anode material 511, anode current collector 512, cathode material 513, cathode current collector 514, separator 515, anode tab, cathode tab 517, pouch material 518, heat sink 530, pressure member 550, outer casing 560, negative terminal 562, positive terminal 564, communication device 565, and temperature sensor 570 will not be described in detail herein.

[0037] 5B , the separator 515, the cathode tab 517, and the pouch material 518 are folded at an angle relative to the anode material 511 and the cathode material 513. In some embodiments, the anode tab can be folded at an angle relative to the anode material 511 and the cathode material 513. As shown, the separator 515, the cathode tab 517, and the pouch material 518 form an angle of approximately 90 degrees relative to the length or width dimension of the anode material 511 and the cathode material 513. In some embodiments, the separator 515, anode tab 516, cathode tab 517, and / or pouch material 518 can form an angle of about 80 degrees, about 85 degrees, about 90 degrees, about 95 degrees, about 100 degrees, about 105 degrees, about 110 degrees, about 115 degrees, about 120 degrees, about 125 degrees, or about 130 degrees relative to the length or width dimension of the anode material 511 and the cathode material 513, including all values ​​and ranges therebetween.

[0038] The separator 515, cathode tab 517, and pouch material 518 are folded to minimize the distance between the inside surface of the frame 520 and the leading edge of the anode material 511 and / or cathode material 513. Minimizing this distance can minimize the amount of unused space within the electrochemical cell module 500. In some embodiments, the distance between the frame 520 and the leading edge of the anode material 511 and / or cathode material 513 is less than about 2 mm, less than about 1.9 mm, less than about 1.8 mm, less than about 1.7 mm, less than about 1.6 mm, less than about 1.5 mm, less than about 1.4 mm, less than about 1.3 mm, less than about 1.2 mm, less than about 1.1 mm, less than about 1 mm, less than about 900 μm, less than about 80 μm, less than about 1.5 mm ... 0 μm, less than about 700 μm, less than about 600 μm, less than about 500 μm, less than about 400 μm, less than about 300 μm, less than about 200 μm, less than about 100 μm, less than 90 μm, less than about 80 μm, less than about 70 μm, less than about 60 μm, less than about 50 μm, less than about 40 μm, less than 30 μm, less than about 20 μm, or less than about 10 μm, including all values ​​and ranges therebetween. In some embodiments, the cathode tab 517 can be welded to the frame 520. In some embodiments, the anode tab can be welded to the frame 520. In some embodiments, the frame 520 can be welded to the inner wall of the outer casing 560.

[0039] 5B, a bottom surface 518a of the portion of the pouch material 518 that extends beyond the anode material 511 and the cathode material 513 contacts the frame 520. In some embodiments, the bottom surface of the portion of the pouch material 518 that extends beyond the anode material 511 and the cathode material 513 can contact an inner wall of the outer casing 560. In some embodiments, a top surface 518b of the portion of the pouch material 518 that extends beyond the anode material 511 and the cathode material 513 can contact the frame 520. In some embodiments, the top surface of the portion of the pouch material 518 that extends beyond the anode material 511 and the cathode material 513 can contact the outer casing 560. As shown, a bottom surface 518a of the cathode tab 517 contacts the frame 520. In some embodiments, a top surface 518b of the cathode tab 517 can contact the frame 520. In some embodiments, the bottom surface of the cathode tab 517 can contact the inner side wall of the outer casing 560. In some embodiments, the top surface of the cathode tab 517 can contact the inner side wall of the outer casing 560. In some embodiments, the bottom surface 518a of the anode tab 516 contacts the frame 520. In some embodiments, the top surface 518b of the anode tab 516 can contact the frame 520. In some embodiments, the bottom surface of the anode tab 516 can contact the inner side wall of the outer casing 560. In some embodiments, the top surface of the anode tab 516 can contact the inner side wall of the outer casing 560.

[0040] 5A and 5B, the pouch material 518 is folded in a first direction on a first side of the electrochemical cell module 500 and folded in a second direction on a second side of the electrochemical cell module 500 (the second side being opposite the first side). In some embodiments, the pouch material 518 on the first side can form an angle with the pouch material 518 on the second side of at least about 150 degrees, at least about 155 degrees, at least about 160 degrees, at least about 165 degrees, at least about 170 degrees, at least about 175 degrees, at least about 180 degrees, at least about 185 degrees, at least about 190 degrees, at least about 195 degrees, at least about 200 degrees, or at least about 205 degrees. In some embodiments, the pouch material 518 on the first side can form an angle with the pouch material 518 on the second side of about 210 degrees or less, about 205 degrees or less, about 200 degrees or less, about 195 degrees, about 190 degrees or less, about 185 degrees or less, about 180 degrees or less, about 175 degrees or less, about 170 degrees or less, about 165 degrees or less, about 160 degrees or less, or about 155 degrees or less. Combinations of the above-referenced angles are also possible, including all values ​​and ranges therebetween (e.g., at least about 150 degrees and about 210 degrees or less, or at least about 160 degrees and about 200 degrees or less). In some embodiments, the pouch material 518 on the first side can form an angle with the pouch material 518 on the second side of about 150 degrees, about 155 degrees, about 160 degrees, about 165 degrees, about 170 degrees, about 175 degrees, about 180 degrees, about 185 degrees, about 190 degrees, about 195 degrees, about 200 degrees, about 205 degrees, or about 210 degrees.

[0041] FIG. 5C shows details of one of the frames 520. As shown, the frame 520 includes a coupling peg 521, a mounting hole 522, a tab passage 523, and a vent hole 524. In some embodiments, multiple frames 520 can be stacked on top of each other. In some embodiments, the coupling peg 521 can serve to couple one of the frames 520 to another. The coupling peg 521 of the first frame can fit into a cavity below the coupling peg 521 of the second frame. The mounting holes 522 allow the heat sink 530 and / or the pressure plate 550 to be coupled to the frame 520 (e.g., via bolts or screws). The tab passage 523 is a thinned portion of the frame 520 through which tabs (e.g., anode tab 516 and / or cathode tab 517) can pass to connect to adjacent cells. In some embodiments, if the frame 520 is metal, the tab passage 523 can include an insulating material. The vent holes 524 allow for degassing during manufacture of the electrochemical cell module 500. The vent holes 524 can be filled (e.g., with metal) after manufacture of the electrochemical cell module 500 is complete. In some embodiments, the frame can be constructed such that the vent holes 524 are aligned or nearly aligned with one or more vent holes in the pouch material of the electrochemical cell 510. In some embodiments, the vent holes in the pouch material of the electrochemical cell 510 can be the same as or substantially similar to the vent holes 219, as described above with reference to FIGS. 2A-2B.

[0042] 6 illustrates an electrochemical cell 610 according to one embodiment. As shown, the electrochemical cell 610 includes an anode material 611, an anode current collector 612, a cathode material 613, a cathode current collector 614, a separator 615, an anode tab (not shown), a cathode tab 617, and a pouch material 618. The electrochemical cell 610 is in contact with a frame member 620 and a heat sink, and the electrochemical cell 610, frame member 620, and heat sink 630 are contained within an outer casing 660. In some embodiments, the anode material 611, anode current collector 612, cathode material 613, cathode current collector 614, separator 615, anode tab, cathode tab 617, pouch material 618, heat sink 630, and outer casing 660 can be the same as or substantially similar to the anode material 511, anode current collector 512, cathode material 513, cathode current collector 514, separator 515, anode tab, cathode tab 517, pouch material 518, and outer casing 560, as described above with reference to Figures 5A-5C. Accordingly, certain aspects of the anode material 611, anode current collector 612, cathode material 613, cathode current collector 614, separator 615, anode tab, cathode tab 617, pouch material 618, heat sink 630, and outer casing 660 will not be described in detail herein.

[0043] As shown, the cathode tab 617 extends through the frame member 620 via the tab passage 623 and contacts the inner side wall of the outer casing 660. In some embodiments, the tab passage 623 can be the same as or substantially similar to the tab passage 523, as described above with reference to FIGS. 5A-5C. In some embodiments, the cathode tab 617 can be welded to the inner side wall of the outer casing 660. In some embodiments, the cathode tab 617 can be welded to a metal bar (not shown) that is electrically coupled to a positive terminal (not shown). Similarly, the anode tab can extend through the frame member 620 via the tab passage 623 and contacts the inner side wall of the outer casing 660. In some embodiments, the anode tab can be welded to a metal bar (not shown) that is electrically coupled to a positive terminal.

[0044] 7A-7E illustrate a method of forming an electrochemical cell module 700, according to one embodiment. FIG. 7A illustrates an auxiliary view of a bottom casing 760a. FIG. 7B illustrates a stack of electrochemical cells 710 with a pouch material 718 extending from the electrochemical cells 710. In FIG. 7B, the electrochemical cells 710 are shown above the bottom casing 760a and lowered into the bottom casing 760a. FIG. 7C illustrates a stack of electrochemical cells 710 placed within the bottom casing 760a such that the pouch material 718 is folded upward by the walls of the bottom casing 760a. In FIG. 7D, a top casing 760b is shown above the bottom casing 760a and the electrochemical cells 710. The top casing 760b is lowered onto the bottom casing 760a such that the top casing 760b and the bottom casing 760a fit together. As shown, the top casing 760b is smaller than the bottom casing 760a such that the top casing 760b fits inside the bottom casing 760a, creating an additional fold in the pouch material. In some embodiments, the top casing 760b may be larger than the bottom casing 760a such that the top casing 760b fits around the outside of the bottom casing 760a. Figure 7E shows the fully formed electrochemical cell module 700.

[0045] In some embodiments, the bottom casing 760a and / or the top casing 760b can be rigid and inflexible. In some embodiments, the bottom casing 760a and / or the top casing 760b can be constructed of high density polyethylene (HDPE), polypropylene (PP), or any other suitable casing material. In some embodiments, the bottom casing 760a and / or the top casing 760b can have a thickness of at least about 100 μm, at least about 200 μm, at least about 300 μm, at least about 400 μm, at least about 500 μm, at least about 600 μm, at least about 700 μm, at least about 800 μm, at least about 900 μm, at least about 1 mm, at least about 1.5 mm, at least about 2 mm, at least about 2.5 mm, at least about 3 mm, at least about 3.5 mm, at least about 4 mm, or at least about 4.5 mm. In some embodiments, the bottom casing 760a and / or the top casing 760b can have a thickness of about 5 mm or less, about 4.5 mm or less, about 4 mm or less, about 3.5 mm or less, about 3 mm or less, about 2.5 mm or less, about 2 mm or less, about 1.5 mm or less, about 1 mm or less, about 900 μm or less, about 800 μm or less, about 700 μm or less, about 600 μm or less, about 500 μm or less, about 400 μm or less, about 300 μm or less, or about 200 μm or less. Combinations of the above-referenced thicknesses are also possible, including all values ​​and ranges therebetween (e.g., at least about 100 μm and about 5 mm or less, or at least about 500 μm and about 1.5 mm or less). In some embodiments, the bottom casing 760a and / or the top casing 760b can have a thickness of about 100 μm, about 200 μm, about 300 μm, about 400 μm, about 500 μm, about 600 μm, about 700 μm, about 800 μm, about 900 μm, about 1 mm, about 1.5 mm, about 2 mm, about 2.5 mm, about 3 mm, about 3.5 mm, about 4 mm, about 4.5 mm, or about 5 mm.

[0046] 8A-8E illustrate a method of forming an electrochemical cell module 800, according to one embodiment. FIG. 8A illustrates a plan view of a bottom casing sheet 860a. As illustrated, the bottom casing sheet 860a includes perforation lines 861 for folding. FIG. 8B illustrates a stack of electrochemical cells 810 with a pouch material 818 extending from the electrochemical cells. The bottom casing sheet 860a is disposed below the electrochemical cells 810, while the top casing sheet 860b is disposed above the electrochemical cells 810. The bottom casing sheet 860a and the top casing sheet 860b are moved toward the stack of electrochemical cells 810. In some embodiments, the bottom casing sheet 860a and the top casing sheet 860b can be moved toward the stack of electrochemical cells 810 at the same time. In some embodiments, the bottom casing sheet 860a and the top casing sheet 860b can be moved toward the stack of electrochemical cells 810 at different times. 8C shows the bottom casing sheet 860a folded (i.e., along perforation line 861) such that the bottom casing sheet 860a folds over the pouch material 818. As shown in FIG. 8D, the top casing sheet 860b is folded over such that the top casing sheet 860b contacts the bottom casing sheet 860a and contains the electrochemical cells 810. As shown in FIG. 8E, the bottom casing sheet 860a and the top casing sheet 860b are bonded together at bond area 865 to form the electrochemical cell module 800. In some embodiments, the bottom casing sheet 860a and the top casing sheet 860b may be bonded together via tape, adhesive, ultrasonic welding, or any other suitable bonding method, or combination thereof.

[0047] In some embodiments, the bottom casing sheet 860a and / or the top casing sheet 860b may be constructed of a flexible material. In some embodiments, the bottom casing sheet 860a and / or the top casing sheet 860b may be constructed of polyethylene terephthalate (PET) or any other suitable flexible material. In some embodiments, the bottom casing sheet 860a and / or the top casing sheet 860b can have a thickness of at least about 50 μm, at least about 100 μm, at least about 150 μm, at least about 200 μm, at least about 250 μm, at least about 300 μm, at least about 350 μm, at least about 400 μm, at least about 450 μm, at least about 500 μm, at least about 550 μm, at least about 600 μm, at least about 650 μm, at least about 700 μm, at least about 750 μm, at least about 800 μm, at least about 850 μm, at least about 900 μm, or at least about 950 μm. In some embodiments, the bottom casing sheet 860a and / or the top casing sheet 860b can have a thickness of about 1 mm or less, about 950 μm or less, about 900 μm or less, about 850 μm or less, about 800 μm or less, about 750 μm or less, about 700 μm or less, about 650 μm or less, about 600 μm or less, about 550 μm or less, about 500 μm or less, about 450 μm or less, about 400 μm or less, about 350 μm or less, about 300 μm or less, about 250 μm or less, about 200 μm or less, about 150 μm or less, or about 100 μm or less. Combinations of the above-referenced thicknesses are also possible, including all values ​​and ranges therebetween (e.g., at least about 50 μm and about 1 mm or less, or at least about 100 μm and about 400 μm or less). In some embodiments, the bottom casing sheet 860a and / or the top casing sheet 860b can have a thickness of about 50 μm, about 100 μm, about 150 μm, about 200 μm, about 250 μm, about 300 μm, about 350 μm, 400 μm, 450 μm, 500 μm, 550 μm, 600 μm, 650 μm, 700 μm, 750 μm, 800 μm, 850 μm, 900 μm, 950 μm, or about 1 mm.

[0048] 9A-9E illustrate a method of forming an electrochemical cell module 900, according to one embodiment. As shown, the electrochemical cell module 900 includes a plurality of electrochemical cells 910 and a pouch material 918 extending from the electrochemical cells 910. In some embodiments, the electrochemical cells 910 and the pouch material 918 may be the same as or substantially similar to the electrochemical cells 810 and the pouch material 818, as described above with reference to FIGS. 8A-8E. Accordingly, certain aspects of the electrochemical cells 910 and the pouch material 918 will not be described in further detail herein.

[0049] FIG. 9A shows a single electrochemical cell 910 with a pouch material 918 extending from the electrochemical cell 910. FIG. 9B shows an edge of the pouch material 918 partially folded such that a first portion of the pouch material 918 forms an angle with a second portion of the pouch material. FIG. 9C shows a first portion of the pouch material 918 folded over and adhered to a second portion of the pouch material via adhesive 925. FIG. 9D shows a detailed view of box D marked in FIG. 9C. As shown, a first portion of the pouch material 918 is folded over and adhered to a second portion of the pouch material 918 via adhesive 925. In some embodiments, the pouch material 918 can be folded without the use of adhesive 925. In other words, the first portion of the pouch material 918 can be folded over the second portion of the pouch material 918 without being adhered to it. Folding the edges of the pouch material 918 makes the pouch material 918 stiffer and more sturdy than the edges of the unfolded pouch material 918. FIG. 9E shows multiple electrochemical cells 910 stacked to form an electrochemical cell module 900. The stiffness of the folded pouch material 918 can help maintain alignment of the electrochemical cells 910 when placed into a casing (not shown). In some embodiments, a stack of electrochemical cells 910 can be placed into the casing at one time. In some embodiments, the electrochemical cells 910 can be placed into the casing one at a time.

[0050] 10A-10C illustrate a method of forming an electrochemical cell module 1000, according to one embodiment. As shown, the electrochemical cell module 1000 includes an electrochemical cell 1010 with a pouch material 1018. In some embodiments, the electrochemical cell 1010 and the pouch material 1018 may be the same as or substantially similar to the electrochemical cell 918 and the pouch material 918, as described above with reference to FIGS. 9A-9E. Accordingly, certain aspects of the electrochemical cell 1010 and the pouch material 1018 will not be described in further detail herein.

[0051] FIG. 10A shows a stack of electrochemical cells 1010 with side panels 1067 on either side of the stack of electrochemical cells 1010. FIG. 10B shows the edges of the pouch material 1018 in a flat state in contact with the side panels 1067. FIG. 10C shows a stack of electrochemical cells 1010 covered by the side panels 1067, the top panel 1068a, and the bottom panel 1068b. As shown, the side panels 1067 contact the edges of the pouch material 1018 and flatten them to reduce the amount of empty space inside the electrochemical cell module 1000. As shown, the side panels 1067 have a curved shape. The curved shape of the side panels 1067 helps to surround the edges of the pouch material 1018 near the vertical center of the stack of electrochemical cells 1010 so that the edges of the pouch material 1018 are gathered in a common area and do not bend in random directions. In some embodiments, the side panels 1067 can have a sharp V-shape to bring the edges of the pouch material 1018 together.

[0052] In some embodiments, the edges of the pouch material 1018 can be brought together before contacting the side panel 1067. In some embodiments, the edges of the pouch material 1018 can be gathered through the use of a removable tool that presses the edges of the pouch material 1018 closer to the vertical center of the stack of electrochemical cells 1010. This can help ensure that the edges of the pouch material 1018 are in the intended position when the side panel 1067 is attached.

[0053] FIG. 10C shows that the top panel 1068a and the bottom panel 1068b are secured to the side panel 1067. In some embodiments, the top panel 1068a and the bottom panel 1068b may be secured to the side panel 1067 via tape and / or adhesive. In some embodiments, the top panel 1068a and the bottom panel 1068b may help keep the side panel 1067 secured to the stack of electrochemical cells 1010. In some embodiments, an adhesive (not shown) may be used to secure the side panel 1067 to the edge of the pouch material 1018 without including the top panel 1068a or the bottom panel 1068b. In some embodiments, the stack of electrochemical cells 1010 and the side panel 1067 may be placed in a casing (not shown) to form the electrochemical cell module 1000. In some embodiments, the side panel 1067 may be incorporated into the casing.

[0054] Various concepts may be embodied as one or more methods, at least one example of which is provided. The acts performed as part of a method may be ordered in any suitable manner. Thus, an embodiment may be constructed such that acts are performed in an order different from that illustrated, including performing some acts simultaneously despite being shown as sequential acts in the illustrated embodiment. In other words, it should be understood that such functions are not necessarily limited to a particular order of execution, but may be limited to any number of threads, processes, services, servers, etc., that may be executed sequentially, asynchronously, concurrently, in parallel, simultaneously, synchronously, etc., in a manner consistent with the present disclosure. Thus, some of these features may be mutually incompatible in that they cannot exist simultaneously in a single embodiment. Similarly, some features may be applicable to one aspect of an innovation but not to other aspects.

[0055] Additionally, the present disclosure may include other innovations not currently described. Applicant reserves all rights with respect to such innovations, including the right to embody such innovations, to file additional applications, continuation applications, continuation-in-part applications, divisional applications, and the like. It is therefore to be understood that the advantages, embodiments, examples, functions, features, logical, operational, organizational, structural, topological, and / or other aspects of the present disclosure should not be considered limitations on the present disclosure as defined by the embodiments, or limitations on equivalents of the embodiments. Depending on the particular desires and / or characteristics of individual and / or business users, database configurations and / or relational models, data types, data transmission and / or network frameworks, syntax structures, and the like, various embodiments of the technology disclosed herein may be implemented in a manner that allows for great flexibility and customization, as described herein.

[0056] All definitions and those used herein should be understood to control for any dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0057] As used herein, in certain embodiments, the term "about" or "approximately" preceding a numerical value indicates a range of the value plus or minus 10%. When a range of values ​​is given, it is understood that each intervening value between the upper and lower limit of the range (rounded to the nearest tenth of the unit of the lower limit unless the context clearly states otherwise) and any other stated or intervening value in the stated range is included in the disclosure. The upper and lower limits of these smaller ranges may be independently included in the smaller ranges, and are also included within the disclosure, subject to any specifically excluded limits in the stated range. If a stated range includes one or both of the limits, the disclosure also includes ranges excluding one or both of those included limits.

[0058] The phrase "and / or" as used in the present specification and embodiments should be understood to mean "either or both" of the elements so conjoined, i.e., elements that are conjunctive in some cases and disjunctive in other cases. Multiple elements described with "and / or" should be interpreted in the same manner, i.e., "one or more" of the elements so conjoined. Other elements, whether related or unrelated to the elements specifically identified, may optionally be present other than the elements specifically identified by the "and / or" clause. Thus, as a non-limiting example, a reference to "A and / or B", when used in combination with open-ended language such as "comprises", may refer in one embodiment to only A (optionally including elements other than B), in another embodiment to only B (optionally including elements other than A), in yet another embodiment to both A and B (optionally including other elements), etc.

[0059] "Or" as used in the present specification and the embodiments should be understood to have the same meaning as "and / or" defined above. For example, when separating items in a list, "or" or "and / or" shall be interpreted as being inclusive, i.e., including at least one of several or listed elements, and possibly other unlisted items, but also including a plurality of them. Only terms clearly indicated to the contrary, such as "only one of" or "exactly one of," or "consisting of" when used in the embodiments, refer to the inclusion of exactly one element of several or listed elements. In general, as used herein, the term "or" shall only be interpreted to indicate exclusive alternatives (i.e., "one or the other, but not both") when preceded by an exclusive term, such as "either," "one of," "only one of," or "exactly one of." "Consisting essentially of," when used in the embodiments, shall have its ordinary meaning as used in the field of patent law.

[0060] As used herein and in the embodiments, the phrase "at least one" in connection with a list of one or more elements should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed in the list of elements, and not excluding any combination of elements in the list of elements. This definition also allows for the optional presence of elements other than those specifically identified in the list of elements to which the phrase "at least one" refers, whether related or unrelated to the specifically identified element. Thus, as a non-limiting example, "at least one of A and B" (or, equivalently, "at least one of A or B," or, equivalently, "at least one of A and / or B") can refer to at least one A (optionally including elements other than B), in one embodiment where B is absent, and optionally including two or more As; in another embodiment where A is absent, and at least one B (optionally including elements other than A), and in yet another embodiment where at least one A, optionally including two or more As, and at least one B (optionally including other elements), optionally including two or more Bs; etc.

[0061] In the embodiments, as well as in the above specification, all transitional phrases, such as "comprising," "including," "carrying," "having," "containing," "involving," "holding," "composed of," and the like, are understood to be open-ended, i.e., meaning including but not limited to. Only the transitional phrases "consisting of" and "consisting essentially of" shall be closed or semi-closed transitional phrases, respectively, as defined in the United States Patent Office Manual of Patent Examining Procedures, Section 2111.03.

[0062] Although certain embodiments of the present disclosure have been outlined above, many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, the embodiments described herein are illustrative and not limiting. Various changes can be made without departing from the spirit and scope of the present disclosure. Where the methods and steps described above indicate that certain events occur in a particular order, those skilled in the art having the benefit of this disclosure will recognize that the order of certain steps can be changed, and such changes are in accordance with variations of the present invention. Furthermore, some steps may not only be performed sequentially as described above, but may also be performed simultaneously in a parallel process, where possible. Although the embodiments have been particularly shown and described, it will be understood that various changes can be made in form and detail.

Claims

1. A first electrochemical cell, comprising: an anode material disposed on an anode current collector; a cathode material disposed on a cathode current collector; a separator disposed between the anode material and the cathode material, the separator having a size sufficient such that a portion of the separator extends beyond an outer edge of the anode material and an outer edge of the cathode material; and a pouch material covering the first electrochemical cell, the pouch material having a width greater than a width of the separator and a length greater than a length of the separator such that a portion of the pouch material extends beyond an outer boundary of the separator; a second electrochemical cell; and a module case that encloses the first electrochemical cell and the second electrochemical cell; The electrochemical cell module wherein the portion of the pouch material extending beyond the outer edge of the separator is folded at an angle of about 80 degrees to about 110 degrees relative to the anode and cathode materials.

2. 10. The electrochemical cell module of claim 1, further comprising a heat sink disposed between the first electrochemical cell and the second electrochemical cell.

3. 3. The electrochemical cell module of claim 2, wherein the heat sink extends beyond the outer edges of the anode material and the outer edges of the cathode material, and the heat sink is folded so that a portion of the heat sink contacts an interior surface of the module case.

4. 4. The electrochemical cell module according to claim 1, further comprising a temperature sensor disposed between the first electrochemical cell and the second electrochemical cell.

5. 4. The electrochemical cell module according to claim 1, further comprising a frame member disposed around an outer edge of the first electrochemical cell.

6. 6. The electrochemical cell module of claim 5, wherein the frame member includes a passage area through which a portion of at least one of the anode current collector or the cathode current collector passes.

7. The electrochemical cell module of claim 5 further comprising a pressure member coupled to the frame member.

8. 6. The electrochemical cell module of claim 5, wherein the portion of the separator extending beyond the outer edges of the anode material and the cathode material and the portion of the pouch material extending beyond the outer edges of the separator are bonded to the frame member.

9. 4. The electrochemical cell module of claim 1, wherein the portions of the separator extending beyond the outer edges of the anode material and the cathode material are folded at an angle of about 80 degrees to about 110 degrees relative to the anode material and the cathode material.

10. A first electrochemical cell, comprising: an anode material disposed on an anode current collector; a cathode material disposed on a cathode current collector; a first electrochemical cell comprising: a separator disposed between the anode material and the cathode material, the separator having a sufficient size such that a portion of the separator extends beyond an outer edge of the anode material and an outer edge of the cathode material, the separator having a top surface and a bottom surface; a pouch material covering the first electrochemical cell, the pouch material having a width greater than a width of the separator and a length greater than a length of the separator such that a portion of the pouch material extends beyond an outer boundary of the separator, the portion of the pouch material having a top surface and a bottom surface; a second electrochemical cell; and a modular case enclosing the first electrochemical cell and the second electrochemical cell, the modular case including an inner wall; an electrochemical cell module wherein at least one of the top surface or the bottom surface of the portion of the pouch material contacts the inner wall of the module case;

11. 11. The electrochemical cell module of claim 10, wherein the portions of the separator extending beyond the outer edges of the anode material and the cathode material are folded at an angle of about 80 degrees to about 110 degrees relative to the anode material and the cathode material.

12. 12. The electrochemical cell module of claim 10 or 11, wherein the portion of the pouch material extending beyond the outer edge of the separator is folded at an angle of about 80 degrees to about 110 degrees relative to the anode and cathode materials.

13. 12. The electrochemical cell module of claim 10 or 11, further comprising a heat sink disposed between the first electrochemical cell and the second electrochemical cell.

14. 14. The electrochemical cell module of claim 13, wherein the heat sink extends beyond the outer edges of the anode material and the outer edges of the cathode material, and the heat sink is folded so that a portion of the heat sink contacts an interior surface of the module case.

15. 12. The electrochemical cell module of claim 10 or 11, further comprising a temperature sensor disposed between the first electrochemical cell and the second electrochemical cell.

16. 12. The electrochemical cell module of claim 10 or 11, further comprising a frame member disposed around an outer edge of the first electrochemical cell.

17. 17. The electrochemical cell module of claim 16, wherein the frame member includes a pass-through area through which a portion of at least one of the anode current collector or the cathode current collector passes.

18. 17. The electrochemical cell module of claim 16, further comprising a pressure member coupled to the frame member.

19. 12. The electrochemical cell module of claim 10 or 11, wherein the module case includes a vent opening.

20. 12. The electrochemical cell module of claim 10 or 11, wherein the portion of the pouch material is folded such that a first section of the portion of the pouch material that extends beyond the outer boundary of the separator contacts a second section of the portion of the pouch material that extends beyond the outer boundary of the separator.

21. 21. The electrochemical cell module of claim 20, wherein the first section is bonded to the second section via an adhesive.

22. 12. The electrochemical cell module according to claim 10, wherein the module case includes side panels that include curved surfaces.

23. A plurality of electrochemical cells arranged in a stack, each of the plurality of electrochemical cells comprising: an anode material disposed on an anode current collector; a cathode material disposed on a cathode current collector; a separator disposed between the anode material and the cathode material, the separator having a size sufficient such that a portion of the separator extends beyond an outer edge of the anode material and an outer edge of the cathode material; a pouch material having a width greater than a width of the separator and a length greater than a length of the separator such that a portion of the pouch material extends beyond an outer boundary of the separator; the portion of each pouch material extending beyond the outer boundary of the separator has a first side and a second side opposite the first side, the first side being folded against the anode and cathode materials, and the second side being folded at an angle between about 160 degrees and about 200 degrees against the anode and cathode materials and against the first side.

24. 24. The electrochemical cell module of claim 23, further comprising a heat sink disposed between a first electrochemical cell of the plurality of electrochemical cells and a second electrochemical cell of the plurality of electrochemical cells.

25. 25. The electrochemical cell module of claim 23 or 24, wherein the portion of the pouch material extending beyond the outer edge of the separator is folded at an angle of about 80 degrees to about 110 degrees relative to the anode and cathode materials.

Images